Lightweight Rooftop Shelters Case Study
Protecting Rooftop Telecommunications Equipment with Lightweight Fiberglass Enclosures
As part of a recent major infrastructure upgrade in Chicago, Verizon faced the challenge of safeguarding telecommunications equipment on urban rooftops. In many metropolitan areas, wireless communications companies rely on rooftop installations to replace traditional ground-based cell towers. Housing this sensitive equipment requires lightweight yet secure weather-resistant enclosures. Traditional building materials such as cinder block or steel can easily exceed rooftop load limits, so Verizon looked to fiberglass, and they chose Shelter Works to provide an energy-efficient and durable solution that could withstand the environmental conditions presented by winters in the Windy City.
A Custom Fiberglass Solution
Shelter Works custom-engineered and manufactured a fiberglass enclosure measuring 10'-4" x 22' 4-1/2" x 8'. The construction included Shelter Works' standard 1.5" foam insulation, with an R-value of 10, and an estimated weight of only 3,200 lbs. The significantly lower weight of fiberglass—compared to steel or concrete—was a decisive factor, as rooftop load capacity was limited.
The only metal in Shelter Works' standard construction is the assembly screws, meaning that there are no thermal bridges to accelerate heat loss, making for a more energy-efficient solution.
Performance and Benefits
- Lightweight Advantage: At just 3,200 lbs, the fiberglass shelter met rooftop load requirements that would have precluded traditional materials.
- Energy Efficiency: The 1.5" foam core insulation contributes to thermal regulation, using the heat emitted by internal equipment to maintain suitable internal temperatures, even during freezing winter conditions.
- Durability: Shelter Works fiberglass buildings are engineered to withstand high winds and snow loads, making them ideal for Chicago's variable and often extreme weather.
- Rapid Deployment: The shelter's factory-built configuration enabled single-day installation, significantly reducing labor costs and project timelines.
Ease of Installation
The shelter was delivered fully assembled and factory-finished, allowing for rapid deployment. This minimized disruption to ongoing operations and eliminated the need for on-site construction.
Ease of installation was a key project requirement. The prefabricated shelter was lifted into place using a crane and the stainless-steel lifting rings that come standard with every Shelter Works fiberglass enclosure. Bob Erpenbach of United Contracting, the installation contractor, remarked:
"It's such a simple process; it can be done in an afternoon. Because these are lightweight structures, it has become a very standard project. We just clip to the stainless steel lifting rings and a crane hoists it up onto the building—easy as can be!"
Bob Erpenbach - Installation Contractor at United Contracting
Shelter Works delivered a custom fiberglass solution that met Verizon's technical, logistical, and environmental challenges. The fiberglass enclosure provides long-term protection for urban rooftop telecommunications equipment by combining strength and energy efficiency in a lightweight shelter.
For future rooftop telecom installations, fiberglass shelters continue to offer a high-performance alternative to traditional materials, particularly when weight, weather, and speed of deployment are critical factors.